U.S. patent number 11,056,871 [Application Number 16/712,268] was granted by the patent office on 2021-07-06 for vehicle interleaved busbars.
This patent grant is currently assigned to Lear Corporation. The grantee listed for this patent is LEAR CORPORATION. Invention is credited to Miguel Angel Acena, Enric Aparicio Rollan, Youssef Ghabbour, Antonio Martinez Perez, Josep Maria Roset Rubio, Ramon Sanchez Rovira, Antonio Tomas Amenos.
United States Patent |
11,056,871 |
Acena , et al. |
July 6, 2021 |
Vehicle interleaved busbars
Abstract
In at least one embodiment, a busbar assembly for a vehicle is
provided. The assembly includes a printed circuit board (PCB), a
first plate, a second plate, and a third plate. The first plate
supported on the PCB and is configured to enable a first current to
flow in a first direction. The second plate is supported on the PCB
and includes a first portion positioned below the first plate to
enable a second current to flow in a second direction. The third
plate is on the PCB and is positioned below the second plate to
enable the first current to flow in the first direction. The second
current that flows through the second plate is increased through an
effective cross-section of the second plate when the flow of the
second current in the second direction is different than the flow
of the first current in the first direction.
Inventors: |
Acena; Miguel Angel (Valls,
ES), Roset Rubio; Josep Maria (Valls, ES),
Sanchez Rovira; Ramon (Valls, ES), Ghabbour;
Youssef (Valls, ES), Aparicio Rollan; Enric
(Valls, ES), Martinez Perez; Antonio (Valls,
ES), Tomas Amenos; Antonio (Valls, ES) |
Applicant: |
Name |
City |
State |
Country |
Type |
LEAR CORPORATION |
Southfield |
MI |
US |
|
|
Assignee: |
Lear Corporation (Southfield,
MI)
|
Family
ID: |
1000005662804 |
Appl.
No.: |
16/712,268 |
Filed: |
December 12, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02G
5/025 (20130101); B60R 16/03 (20130101); H05K
1/181 (20130101); H05K 2201/10272 (20130101) |
Current International
Class: |
H02G
5/02 (20060101); B60R 16/03 (20060101); H05K
1/18 (20060101) |
Field of
Search: |
;174/88B |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Cerena De Souza for Larsen & Toubro Limited, "Higher Ampacity
of Busbars", Jul.-Sep. 1994, 4 pgs. cited by applicant.
|
Primary Examiner: Tso; Stanley
Attorney, Agent or Firm: Brooks Kushman P.C.
Claims
What is claimed is:
1. A busbar assembly for a vehicle, the assembly comprising: a
printed circuit board (PCB); a first plate supported on the PCB and
having a first current that flows in a first direction; a second
plate supported on the PCB and having a first portion positioned
below the first plate, the second plate having a second current
that flows in a second direction; and a third plate supported on
the PCB and being positioned below the first portion of the second
plate, the third plate having the first current that flows in the
first direction, wherein the second current that flows through the
second plate is increased through an effective cross-section of the
second plate and reduces a parasitic current in the second plate in
response to the flow of the second current in the second direction
being different than the flow of the first current in the first
direction, and wherein the first plate includes a first ramped
section extending below the first plate, and the third plate
includes a second ramped section extending below the second plate
and being axially aligned with the first ramped section.
2. The busbar assembly of claim 1, wherein positioning of the first
plate, the second plate, and the third plate relative to one
another form an interleaved arrangement for the busbar assembly,
and wherein the interleaved arrangement reduces a temperature
across the second plate in response to the flow of the second
current in the second direction being different than the flow of
the first current in the first direction.
3. The busbar assembly of claim 1 further comprising a fourth plate
being separate from the first plate and being supported on the PCB
and wherein the fourth plate includes the first current to flow in
the first direction.
4. The busbar assembly of claim 3, wherein the second plate
includes a second portion that lies in a same plane of the first
portion and is positioned below the fourth plate.
5. The busbar assembly of claim 4 further comprising a fifth plate
supported on the PCB and being positioned below the second portion
of the second plate to provide the first current to flow in the
first direction.
6. The busbar assembly of claim 5, wherein the first plate and the
fourth plate are positioned on the same plane with one another and
wherein the third plate and the fifth plate are positioned on the
same plane with one another.
7. A busbar assembly for a vehicle, the assembly comprising: a
printed circuit board (PCB); a first plate supported on the PCB and
having a first current that flows in a first direction; a second
plate supported on the PCB and having a first portion positioned
below the first plate, the second plate having a second current
that flows in a second direction; and a third plate supported on
the PCB and being positioned below the first portion of the second
plate, the third plate also having the first current that flows in
the first direction, wherein a positioning of the first plate, the
second plate, and the third plate relative to one another form an
interleaved arrangement, and wherein the interleaved arrangement
reduces a temperature across the second plate and reduces a
parasitic current in the second plate in response to the flow of
the second current in the second direction being different than the
flow of the first current in the first direction, and wherein the
first plate includes a first ramped section extending below the
first plate, and the third plate includes a second ramped section
extending below the second plate and being axially aligned with the
first ramped section.
8. The busbar assembly of claim 7, wherein the second current of
the second plate is increased through an effective cross-section of
the second plate in response to the flow of the second current in
the second direction being than the flow of the first current in
the first direction.
9. The busbar assembly of claim 7, wherein the first plate includes
a first extending section that is spaced apart and parallel to the
first portion of the second plate and to the PCB.
10. The busbar assembly of claim 7 further comprising a fourth
plate being separate from the first plate and being supported on
the PCB, the fourth plate also having the first current that flows
in the first direction.
11. The busbar assembly of claim 10, wherein the second plate
includes a second portion positioned below the fourth plate.
12. The busbar assembly of claim 11 further comprising a fifth
plate supported on the PCB and being positioned below the second
portion of the second plate, the fifth plate also having the first
current that flows in the first direction.
13. The busbar assembly of claim 12, wherein the first plate and
the fourth plate are positioned on a same plane with one another
and wherein the third plate and the fifth plate are positioned on
the same plane.
14. A busbar assembly for a vehicle, the assembly comprising: a
first plate including a first current that flows in a first
direction; a second plate having a first portion and being
positioned adjacent to the first plate, the second plate including
a second current that flows in a second direction; and a third
plate being positioned adjacent the first portion of the second
plate, the third plate including the first current that flows in
the first direction, wherein a positioning of the first plate, the
second plate, and the third plate relative to one another form an
interleaved arrangement, wherein the interleaved arrangement
reduces a parasitic current in the second plate and a temperature
across the second plate in response to the flow of the second
current in the second direction being different than the flow of
the first current in the first direction, and wherein the first
plate includes a first ramped section extending below the first
plate, and the third plate includes a second ramped section
extending below the second plate and being axially aligned with the
first ramped section.
15. The busbar assembly of claim 14, wherein the second current of
the second plate is increased through an effective cross-section of
the second plate in response to the flow of the second current in
the second direction being different than the flow of the first
current in the first direction.
16. The busbar assembly of claim 14 further comprising a printed
circuit board (PCB) being positioned below the first plate, the
second plate, and the third plate for supporting the first plate,
the second plate, and the third plate.
Description
TECHNICAL FIELD
Aspect disclosed herein may generally related to interleaved
busbars in a vehicle. Specifically, aspects disclosed herein may
generally relate to interleaved busbars that are used in connection
with a direct current (DC) to DC converter in a vehicle or in other
vehicle electrification systems that handle high currents at medium
to high frequencies. These aspects and others will be discussed in
more detail below.
BACKGROUND
U.S. Pat. No. 9,966,584 to Jan et al. discloses a battery pack that
includes a busbar at one end, freeing the other end of the battery
pack for cooling or other arrangements. A plurality of battery
cells has first terminals of the battery cells at first ends of the
battery cells. Portions of second terminals of the battery cells
are at the first ends of the battery cells. The first ends of the
battery cells are in a coplanar arrangement. A plurality of busbars
is assembled proximate to the first ends of the battery cells. The
busbars are coupled to the first terminals and the second terminals
of the battery cells at the first ends of the battery cells to
place the battery cells in one of a series connection, a parallel
connection or a series and parallel connection.
SUMMARY
In at least one embodiment, a busbar assembly for a vehicle is
provided. The assembly includes a printed circuit board (PCB), a
first plate, a second plate, and a third plate. The first plate
supported on the PCB and is configured to enable current to flow in
a first direction. The second plate is supported on the PCB and
includes a first portion positioned below the first plate to enable
current to flow in a second direction. The third plate is supported
on the PCB and is positioned below the second plate to enable
current to flow in the first direction. The second current that
flows through the second plate is increased through an effective
cross-section of the second plate when the flow of the second
current in the second direction is different than the flow of the
first current in the first direction.
In at least another embodiment, a busbar assembly for a vehicle is
also provided. The assembly includes a printed circuit board (PCB),
a first plate, a second plate, and a third plate. The first plate
supported on the PCB and is configured to enable current to flow in
a first direction. The second plate is supported on the PCB and
includes a first portion positioned below the first plate to enable
current to flow in a second direction. The third plate is supported
on the PCB and is positioned below the second plate to enable
current to flow in the first direction. The positioning of the
first plate, the second plate, and the third plate relative to one
another form an interleaved arrangement. The interleaved
arrangement reduces a parasitic current in the second plate when
the flow of the second current in the second direction is different
than the flow of the first current in the first direction.
In at least another embodiment, a busbar assembly for a vehicle is
also provided. The assembly includes a first plate, a second plate,
and a third plate. The first plate is configured to enable current
to flow in a first direction. The second plate includes a first
portion positioned below the first plate that is positioned
adjacent to the first plate to enable current to flow in a second
direction. The third plate is positioned adjacent to the second
plate to enable current to flow in the first direction. The
interleaved arrangement reduces a parasitic current in the second
plate when the flow of the second current in the second direction
is different than the flow of the first current in the first
direction
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present disclosure are pointed out with
particularity in the appended claims. However, other features of
the various embodiments will become more apparent and will be best
understood by referring to the following detailed description in
conjunction with the accompany drawings in which:
FIG. 1 depicts a system including a busbar assembly for a vehicle
in accordance to one embodiment;
FIG. 2 depicts a skin effect of a busbar assembly;
FIG. 3 depicts various examples of a proximity effect for the
busbar assembly;
FIG. 4 depicts an example of the proximity effect for the busbar
assembly in accordance to one embodiment;
FIG. 5 depicts a perspective view of the busbar assembly in
accordance to one embodiment;
FIG. 6 depicts an exploded view of the busbar assembly in
accordance to one embodiment;
FIG. 7 depicts a cross-sectional view of the busbar assembly in
accordance to one embodiment;
FIG. 8 depicts a perspective view of the busbar assembly in
accordance to one embodiment;
FIG. 9 depicts another perspective view of the busbar assembly in
accordance to one embodiment;
FIG. 10 depicts another perspective view of the busbar assembly in
accordance to one embodiment;
FIG. 11 depicts an exploded underside view of the busbar assembly
in accordance to one embodiment; and
FIG. 12 depicts a cross-sectional view of the busbar assembly along
with a first spacer and a second spacer in accordance to one
embodiment.
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are
disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention that
may be embodied in various and alternative forms. The figures are
not necessarily to scale; some features may be exaggerated or
minimized to show details of particular components. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting, but merely as a representative basis
for teaching one skilled in the art to variously employ the present
invention.
It is recognized that directional terms that may be noted herein
(e.g., "upper", "lower", "inner", "outer", "top", "bottom", etc.)
simply refer to the orientation of various components of a busbar
assembly as illustrated in the accompanying figures. Such terms are
provided for context and understanding of the embodiments disclosed
herein.
A vehicle DC/DC converter may facilitate a transfer of current
anywhere between 200-250 Amps. The DC/DC converter may include
various switches that are switched in a frequency range of 100-200
KHz. Generally, a transformer is coupled to the DC/DC converter by
way of busbars. The busbars may exhibit various conditions that
adversely affect performance such as a skin effect and a proximity
effect. With the skin effect, current may flow on a limited surface
of the busbar in response to cycling switching devices at a mid or
high frequency. For example, current may flow on an exterior
portion of the overall cross section of the bus and not on an
interior portion of the busbar. With the proximity effect,
parasitic currents may be present in the busbar assembly which may
increase a temperature of the busbars and cause an overheating
condition. For example, a plurality of busbars may suffer from
severe skin plus proximity effects while current flows that may
reach temperatures that may be too high for electronic circuits
that are positioned proximate to these busbars. Over-temperature
protection (elements or components) are configured to react on a
temperature increase and disable the protected device. The
monitored temperature may increase because of ambient temperature
increase or because excessive power is being dissipated in the
monitored device. The protection element may then disconnect the
monitored (protected) device (e.g., the protection element may
either open the power path or disable the activating control). When
busbars exceed a predetermined temperature, the environmental
temperature or the area surrounding the busbars increases as well
and the protection elements disable the protected devices. In the
end, the overall electronic system remains inoperative. In general,
such an increase in ambient temperature attributed to an increase
in heat generated by the busbars may not be expected. It is
desirable to avoid rendering the overall electronic system
inoperative due to this aspect.
The embodiments as set forth herein generally provide for a busbar
assembly that includes various busbars interleaved with one
another. Such an arrangement may maximize the overall cross section
of the busbar that current can flow on and may also provide heat
dissipation thereby resulting in minimal resistance losses.
Additionally, the disclosed busbar assembly may also remove the
potential for a temperature increase in the ambient to prevent
unexpected electronic system shutdown. These aspects and others
will be discussed in more detail herein.
FIG. 1 depicts a system 100 including a busbar assembly 114 for a
vehicle in accordance to one embodiment. The system 100 generally
corresponds to a power converter system (or DC/DC converter) in a
vehicle 102 that may convert high voltage (HV) on a HV bus 104 into
a low voltage (LV) on a LV bus 106. The system 100 may also store
the low voltage LV on one or more vehicle batteries 107 in the
vehicle 102.
The system 100 includes a plurality of first switching devices
108a-108n, a resonance circuit 110, a transformer 112, a busbar
assembly 114 (or a plurality of busbars 121, 123, 125), and a
plurality of second switching devices 116a-116n. In general, a
controller 113 controls the plurality of switching device 108a-108n
to selectively activate and deactivate at a switching frequency
which thereby generates an alternating current (AC). The resonance
circuit 110 generally provides a capacitance or inductance to an
output provided by the plurality of first switching devices
108a-108n. The transformer 112 may decrease the voltage output of
the AC based signal from the resonance circuit 110. In one example,
the transformer 112 may be formed of a center tap configuration. In
one example, the transformer 112 includes a primary side 115 and a
secondary side 117. The secondary side 117 may be formed of two
coils that provide contacts (or connections) 119a, 119b, and 119n.
The contacts 119a, 119b, and 119n are coupled to the plurality of
busbars 121, 123, 125, respectively. The plurality of busbars 121,
123, and 125 receive the decreased AC based signal. The controller
113 controls the plurality of second switching devices 116a-116n to
rectify the stepped down AC based signal into a DC signal (e.g.,
low voltage DC signal) for storage on the battery 107 or to
directly supply loads. While the system 100 generally illustrates a
single direction flow with respect to the flow of energy from the
HV bus 104 to the LV bus 106, it is recognized that the system 100
may also be adapted to enable the flow of energy from the LV bus
106 to the HV bus 104 while utilizing the plurality of busbars 121,
123, and 125 as set forth herein.
FIG. 2 depicts a skin effect of a busbar assembly. In general, a
busbar assembly (i.e., one or more busbar) may exhibit the skin
effect given that the plurality of first switching device 108a-108n
are driven by the controller 113 at a switching frequency. As
generally shown at 200, at a lower switching frequency, current may
pass through the busbar assembly consistently across the entire
cross section of the busbar. However, as generally shown at 202, at
middle to higher switching frequencies, current may flow through
the busbar at top and bottom surfaces of the busbar assembly. Thus,
current flows through the busbar assembly on a limited surface area
of the busbar which minimizes performance (i.e., cross sectional
area of busbar is minimized that enables flow of current through
the busbar).
FIG. 3 depicts various examples of a proximity effect for the
busbar assembly. As generally shown at 204, a cross sectional view
of a first busbar 250 and a second busbar 252 is generally shown.
When current flows through the first busbar 250 and the second
busbar 252 in the same direction, the current flows on a top side
254 of the first busbar 250 and on a bottom side 256 of the second
busbar 252. In the scenario presented in 204, the skin effect
concentrates the current on the top side 254 of the first busbar
250 and on the bottom side 256 of the second busbar 252. Thus,
current flowing in the first busbar 250 and the second busbar 252
is minimized since the current flows in a smaller cross-sectional
area of the first busbar 250 and the second busbar 252.
As generally shown at 206, a cross-sectional view of the first
busbar 250 and the second busbar 252 is shown. When current flows
through the first busbar 250 and the second busbar 252 in an
opposite direction, the current flows through a bottom side 258 of
the first busbar 250 and current flows through a top side 260 of
the second busbar 252, respectively. Thus, current flowing in the
first busbar 250 and the second busbar 252 is minimized since the
current flows in a smaller region or smaller cross-sectional area
of the first busbar 250 and the second busbar 252.
As generally shown at 208, a cross-sectional view of the first
busbar 250, the second busbar 252, and a third busbar 270 is
illustrated. The current flows through the first busbar 250 and the
second busbar 252 similarly to that illustrated in 206. However,
parasitic current is present in the third busbar 270 thus providing
a net zero current value. For example, the third busbar 270
exhibits parasitic current that travels on a top side and a bottom
side of the third busbar 270 thereof in opposite directions. This
aspect may increase the overall temperature of the busbars 250,
252, and 254.
As generally shown at 210 in reference to FIG. 4, a top view of the
first busbar 250, the second busbar 252, the third busbar 270, and
a fourth busbar 272 is illustrated. The fourth busbar 272 may be
added in an attempt to increase current flow. The current flows
through the first busbar 250 and the second busbar 252 similarly to
that illustrated in 206. This arrangement illustrated at 210 shows
that parasitic currents 280a, 280b, 280c, and 280n are present on
both the top and bottom sides of the third busbar 270 and the
fourth busbar 272 which leads to an additional increase in
temperature.
FIG. 5 depicts a perspective view of the busbar assembly 114 and
FIG. 6 depicts an exploded view of the busbar assembly 114 in
accordance to one embodiment. The busbar assembly 114 is generally
arranged in an interleaved manner of bus plates 121, 123, and/or
125. For example, busbar 121 may be formed of an upper plate 121a
and a lower plate 121b, busbar 123 may be formed of a first center
plate 123a and a second center plate 123b, and busbar 125 may be
formed of an upper plate 125a and a lower plate 125b. The upper
plate 121a and the lower plate 121b of the busbar 121 may be
coupled to the connection 119a on the secondary side 117 of the
transformer 112. The upper plate 121a and the lower plate 121b
generally enable current flow to return back to the secondary side
117 of the transformer 112. The first center plate 123a and the
second center plate 123b of the busbar 123 may be coupled to the
connection 119b on the secondary side 117 of the transformer 112.
The first center plate 123a and the second center plate 123b of the
busbar 123 enables current to flow from the secondary side 117 of
the transformer 112 to the LV bus 106. The upper plate 125a and the
lower plate 125b of the busbar 125 may be coupled to the connection
119n on the secondary side 117 of the transformer 112. The upper
plate 125a and the lower plate 125b of the busbar 125 generally
enable current flow or return back to the secondary side 117 of the
transformer 112. The busbars 121, 123, and 125 are generally
connected to a printed circuit board (PCB) 302. The various
electronics as noted above in connection with FIG. 1 may also be
coupled to the PCB 302. In one example, the PCB 302 may generally
lie in a horizontal plane.
Each of the busbars 121, 123, and 125 includes at least one
extending section that extends horizontally above the PCB 302. In
the example illustrated in FIG. 6 for the busbar 121, the upper
plate 121a includes a first extending section 320a and the lower
plate 121b includes a second extending section 320b. For the busbar
123, the first center plate 123a includes a first extending section
322a and the second center plate 123b includes a second extending
section 322b. For the busbar 125, the upper plate 125a includes a
first extending section 324a and the lower plate 125b includes a
second extending section 324b. Each of the first extending sections
320a, 322a, 324a and the second extending sections 320b, 322b, and
324b extend over the PCB 302. In one example, each of the first
extending sections 320a, 322a, 324a and the second extending
sections 320b, 320b, 324b may be axially spaced apart from the PCB
302 (or parallel to a top surface of the PCB 302).
For the busbar 121, the upper plate 121a includes a first coupling
section 340a (see FIG. 7) having connection portions 341 and the
lower plate 121b includes a second coupling section 340b each
having connection portions 343 for coupling to the PCB 302 (see
also FIGS. 6 and 7). The first coupling section 340a and the second
coupling section 340b are generally perpendicular or orthogonal to
the first extending section 320a and the second extending section
320b. The connection portions 341 of the upper plate 121a are
spaced apart from one another. The connection portions 343 of the
lower plate 121b are spaced apart from one another. Additionally,
the upper plate 121a includes a ramped portion 360a and a coupling
section 362a. The lower plate 123b includes a ramped portion 360b
and a coupling section 362b. A fastening mechanism (not shown) may
be inserted into an opening formed in the coupling sections 362a,
362b. The coupling sections 362a-362b may extend beyond the PCB 302
to enable fastening mechanisms (not shown) to be couple the busbar
121 to the connection 119a (of a transformer).
The first center plate 123a and the second center plate 123b of the
busbar 123 each include a first coupling section 342a and a second
coupling section 342b (see FIGS. 6-8). It is recognized that the
first center plate 123a and the second center plate 123b are
separate from one another but that the first center plate 123a and
the second center plate 123b may be coupled to the same holes in
the PCB 302 via the first coupling section 342a and the second
coupling section 342b for each of the first center plate 123a and
the second center plate 123b, respectively. The first coupling
section 342a for each of the first center plate 123a and the second
center plate 123b may be positioned at a rear of the busbar 123 and
extend along a first axis 345. The second coupling section 342b for
each of the first center plate 123a and the second center plate
123b may be positioned between the first extending section 322a and
the second extending section 322b and may extend along a second
axis 347 of the busbar 123. The first axis 345 may generally be
perpendicular to the second axis 347. Each of the first coupling
sections 342a for the first center plate 123a and the second center
plate 123b include connection portions 351a-351x for coupling to
the PCB 302. The first coupling section 342a and the second
coupling section 342b are generally perpendicular or orthogonal to
the first extending section 322a and the second extending section
322b. The connection portions 351a-351x are spaced apart from one
another. Additionally, the first center plate 123a includes a first
ramped portion 370a and a first coupling section 372a. The second
center plate 123b includes a second ramped portion 370b and a
second coupling section 372b. The first ramped portion 370a may be
positioned behind the second ramped portion 370b and the first
coupling section 372a may be positioned below the second coupling
section 372b The fastening mechanism (not shown) may be inserted
into an opening formed in the first coupling section 372a to couple
the busbar 123 to the PCB 302.
The busbar 125 includes a first coupling section 344a and a second
coupling section 344b. The first coupling section 344a include
connection portions 355a-355x and the second coupling section 344b
include connection portions 357a-357x for coupling to the PCB 302.
The first coupling section 344a and the second coupling section
344b are generally perpendicular or orthogonal to the first
extending section 324a and the second extending section 324b. The
connection portions 355a-355x and the connection portions 357a-357x
are spaced apart from one another. Additionally, the upper plate
125a includes a ramped portion 380a and a coupling section 382a.
The lower plate 125b includes a ramped portion 380b and a coupling
section 382b. The fastening mechanism (not shown) may be inserted
into an opening formed in the coupling sections 382a, 382b to
couple the bottom plate 114n to the PCB 302.
FIG. 7 generally depicts a front-cross sectional view of the busbar
assembly 114 in accordance to one embodiment. The view of the
busbar assembly 114 does not include the various ramped portions
360a, 360b, 370a, 370b, 380a, 380b and the coupling sections 362a,
362b, 372a, 372b, 382a, 382b for the corresponding busbars 121,
123, and 125 to illustrate the coupling sections 340a, 340b, 342a,
342b, 344a, and 344b. The first coupling section 340a is positioned
directly adjacent to the second coupling section 340b of the busbar
121. A corresponding pair of connection portions 341 and 343 for
the busbar 121 may be inserted into a single through hole within
the PCB 302. The first coupling section 344a are positioned
directly adjacent to the second coupling section 344b of the busbar
125.
FIG. 8 depicts a perspective view of the busbar assembly 114 in
accordance to one embodiment. View 400 is provided which generally
depicts an effective current flow through a cross section of the
upper plate 121a and the lower plate 121b of the busbar 121 and the
first center plate 123a of the busbar 123. The first center plate
123a of the busbar 123 is generally positioned between the upper
plate 121a and the lower plate 121b. It is recognized that view 400
may also correspond to the upper plate 125a and the lower plate
125b of the busbar 125 and the second center plate 123b of the
busbar 123. The second center plate 123b of the busbar 123 is
generally positioned between the upper plate 125a and the lower
plate 125b. As noted above, the busbars 121 and 125 generally
enable current flow to return back to the secondary side 117 of the
transformer 112 in the system 100. The busbar 123 enables current
to flow from the secondary side 117 of the transformer 112 to the
LV bus 106 in the system 100. As shown for the busbar 121, current
flows on a bottom section of the upper plate 121a thereof that is
closer in proximity to the first center plate 123a. Likewise,
current flows in an opposite direction on a top section of the
first center plate 123a that is closer in proximity to the upper
plate 121a. Additionally, current flows in the same direction on a
bottom section of the first center plate 123a that is closer in
proximity to a top section of the lower plate 121b. Also, current
flows in an opposite direction on the top section of the lower
plate 124b that is closer in proximity to a bottom section of the
first center plate 123a. Thus, the effective current that flows
across the busbar 123 (the first center plate 123a or the second
center plate 123b) is generally doubled. This arrangement utilizes
a greater cross-sectional surface area (or effective
cross-sectional surface area) of the busbar 123 to enable current
to pass therethrough. This arrangement may also decrease the
temperature across the busbar 123 by roughly half since the
generation of parasitic currents may be avoided due to the
interleaved nature as set forth herein of the busbars 121, 123,
and/or 125.
FIG. 9 depicts another perspective view of a portion of the busbar
assembly 114 in accordance to one embodiment. The busbar assembly
114 as depicted in FIG. 9 does not illustrate the busbars 121 and
125. The busbar assembly 114 includes a first spacer 500 and a
second spacer 502. As shown, the first spacer 500 is positioned
directly on top of the first center plate 123a and the second
center plate 123b to prevent these plates from coming into physical
contact with the upper plate 121a of the busbar 121 and the upper
plate 125a of the busbar 125. The second spacer 502 is positioned
directly below the first center plate 123a and the second center
plate 123b to prevent these plates from coming into physical
contact with the lower plate 121b of the busbar 121 and the lower
plate 125b of the busbar 125. As shown in view 400 of FIG. 8. Given
that the first center plate 123a and the second center plate 123b
enable current to flow in a different direction from the plates
121a, 121b, 125a, 125b of the busbars 121 and 125, the first and
second center plates 123a, 123b are physically isolated from the
plates 121a, 121b, 125a, 125b of the busbars 121 and 125.
The first spacer 500 prevents the first extending section 322a and
the second extending section 322b of the busbar 123 from contacting
an underside of the first extending section 320a of the busbar 121
and the first extending section 324a of the busbar 125. The second
spacer 502 prevents the first extending section 322a and the second
extending section 322b of the busbar 123 from contacting a top side
of the second extending section 320b of the busbar 121 and a top
side of the second extending section 324b of the busbar 125.
The first spacer 500 includes a first spacer ramped portion 520a
and a second spacer ramped portion 520b. The first spacer ramped
portion 520a and the second spacer ramped portion 520b are
positioned underneath the ramped portion 360a of the busbar 121 and
the ramped portion 380a of the busbar 125 to prevent contact
between the busbars 121 and 123. The second spacer 502 includes a
first spacer ramped portion 522a and a second spacer ramped portion
522b. The first spacer ramped portion 522a and the second spacer
ramped portion 522b are positioned underneath the ramped portions
370a, 370b of the busbar 123 to prevent contact between the busbar
123 and 125. The second spacer 502 generally includes a plurality
of guiding tabs 550a-550n that are positioned on a wall 552 thereof
to receive and guide the lower plate 125b of the busbar 125 to the
second spacer 502. The plurality of guiding tabs 550a-550n may
ensure that the busbars 121 and 125 do not separate from the busbar
123. While not shown, the plurality of guiding tabs 550a-550n may
be positioned on the other side of the wall 552 (i.e., facing into
the page) to receive and guide the lower plate 121b of the busbar
121 to the second spacer 502. While also not shown, the first
spacer 500 may also include on the wall 552, a plurality of guiding
tabs 550a-550n to receive and guide the upper plate 121a of the
busbar 121 and the upper plate 125a of the busbar 125 to the first
spacer 500.
FIG. 10 depicts a cross-sectional view of the busbar assembly 114
(e.g., only the busbars 123 and 125) including the first spacer 500
and the second spacer 502 in accordance to one embodiment. The
first spacer 500 further includes an upper surface 500a to isolate
the busbar 121 and the busbar 125 laterally. The first spacer 500
includes the guiding tabs 550a-550b to hold the busbars 121 and 125
in place thereby preventing the busbars 121 and 125 from moving
upward. The first spacer 500 and the second spacer 502 includes a
corresponding wall (not shown) that includes the plurality of
guiding tabs 550a-550n to receive the busbar 123 to the busbar 125.
FIG. 11 depicts an exploded underside view of the busbar assembly
114 in accordance to one embodiment.
FIG. 12 depicts another cross-sectional view of the busbar assembly
114 along with the first spacer 500 and the second spacer 502 in
accordance to one embodiment. The first spacer 500 includes a first
dividing section 600 that isolates the upper plate 121a of the
busbar 121 from the upper plate 125a of the busbar 125. As shown,
the first dividing section 600 may be U-shaped. It is recognized
that the first dividing section 600 may take on any number of
shapes to isolate the upper plate 121a of the busbar 121 from the
upper plate 125a of the busbar 125. Similarly, the second spacer
502 may include a second dividing section 602a that isolates the
lower plate 121b of the busbar 121 from the first center plate 123a
of the busbar 123. The second spacer 502 may also include a third
dividing section 602b that isolates the lower plate 125b from the
second center plate 123b of the busbar 123.
While the first spacer 500 and the second spacer 502 are generally
configured to receive the various busbars 121, 123, 125, portions
of the busbars 121, 123, and 125 are fixed to themselves. For
example, the first coupling section 340a of the upper plate 121a
and the second coupling section 344b of the lower plate 121b may be
welded or riveted together to fix the upper plate 121a and the
lower plate 121b of the busbar 121 to one another. Additionally, or
alternatively, the coupling sections 362a, 362b of the busbar 121
may be riveted or soldered to one another. Likewise, the first
coupling section 342a of the first center plate 123a and the second
center plate 123b of the busbar 123 may be welded or riveted
together. Additionally, or alternatively, the coupling sections
372a, 372b of the busbar 123 may be riveted or soldered to one
another. The second coupling section 342b of the first center plate
123a and the second center plate 123b may be welded or riveted
together. The first coupling section 344a of the upper plate 125a
and the second coupling section 344b of the lower plate 125b may be
welded or riveted together to fix the upper plate 125a to the lower
plate 125b together. Additionally, or alternatively, the coupling
sections 382a, 382b of the busbar 125 may be riveted or soldered to
one another. The entire assembly 114 may be soldered to the PCB
302.
While exemplary embodiments are described above, it is not intended
that these embodiments describe all possible forms of the
invention. Rather, the words used in the specification are words of
description rather than limitation, and it is understood that
various changes may be made without departing from the spirit and
scope of the invention. Additionally, the features of various
implementing embodiments may be combined to form further
embodiments of the invention.
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